Direct-chill semi-continuous casting process of three-layer composite ingot of 4045/3004/4045 aluminum alloys

Three-layer composite ingot of 4045/3004/4045 aluminum alloys was prepared by direct-chill semi-continuous casting process, the temperature field distribution near the composite interface, macro-morphology, microstructure and composition distribution of the composite interface were investigated. The results show that semi-solid layer with a certain thickness forms near the interface due to the effect of cooling plate, which ensures successful implementation of casting the composite ingot. Two different aluminum alloys are well bonded metallurgically. The mechanical properties of composite interface were measured, the tensile and shearing strengths of composite interface are 105 and 88 MPa, respectively, which proves that the composite interface is a kind of metallurgical bonding.